Abstract
Gas detonation forming is a high-speed forming method, which has the potential to form complex geometries, including sharp angles and undercuts, in a very short process time. Despite many efforts being made to develop detonation forming, many important aspects remain unclear and have not been studied experimentally, nor numerically in detail, e.g., the ability to produce sharp corners, the effect of peak load on deformation and damage location and its propagation in the workpiece. In the present work, DC04 steel cups were formed using gas detonation forming, and finite element method (FEM) simulations of the cup forming process were performed. The simulations on 3D computational models were carried out with explicit dynamic analysis using the Johnson–Cook material model. The results obtained in the simulations were in good agreement with the experimental observations, e.g., deformed shape and thickness distribution. Moreover, the proposed computational model was capable of predicting the damage initiation and evolution correctly, which was mainly due to the high-pressure magnitude or an initial offset of the workpiece in the experiments.
Highlights
Sheet metal forming basically consists of stretching and bending a thin sheet into the desired shape.The produced parts can be stiff and have good strength-to-weight ratios; these products are widely used for automobiles, domestic appliances, aircraft and food and drink cans
Many aspects of sheet metal forming processes have been widely studied using electromagnetic forming, especially with regard to the behavior of materials under a high strain rate, the possible future applications and numerical modeling of the process, with several works dedicated to these topics [1,2,3,4,5,6,7]
A small hole is drilled through both the die holder and die, which is connected to a vacuum pump. This is done to prevent the formation of an air cushion between the sheet metal and the die, enabling the sheet metal to perfectly sit into the die
Summary
Sheet metal forming basically consists of stretching and bending a thin sheet into the desired shape.The produced parts can be stiff and have good strength-to-weight ratios; these products are widely used for automobiles, domestic appliances, aircraft and food and drink cans. DC04 steel has a good ductility level, which facilitates the production of complicated component shapes where required and even allowing deep pressing processes to be carried out. Cup formation of DC04 steel sheets was studied using the gas detonation forming technique. It is a highly dynamic manufacturing method, which involves the release of the stored energy in a very short interval of time. There are various high-speed forming processes, which are classified based on the type of energy transfer. This can be done by active media, accelerated mass or by active energy
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